Mixture Design and Mechanical Properties of Recycled Mortar and Fully Recycled Aggregate Concrete Incorporated with Fly Ash

Recycled aggregate concrete (RAC) is a sort of green, low carbon, environmental protection building material, its application is of great significance to the low carbonization of the construction industry. The performance and strength of RAC are much lower than natural aggregate concrete (NAC), which are the key factors restricting its application. Class F fly ash is a cementitious material that is considered environmentally hazardous. In this paper, appropriate water-binder (w/b) ratios were found through a mortar expansion test at first. The compressive strength of recycled mortar incorporated with class F fly ash was further studied. On this basis, the mechanical properties of nine groups of fully recycled aggregate concrete (FRAC) with a w/b ratio of 0.3, 0.35, and 0.4, and fly ash replacement ratios of 0, 20%, and 40%, were studied. The influence of the w/b ratio and fly ash replacement ratio on mechanical properties was analyzed and compared with previous research results. In addition, the conversion formulas between the splitting tensile strength, flexural strength, and compressive strength of FRAC were fitted and established. The research results have a certain guiding significance for the mixture design of FRAC and further application of class F fly ash.     

Selected Properties of Self-Compacting Concrete with Recycled PET Aggregate

In this paper, the issue of self-compacting concrete (SCC) with the addition of polyethylene terephthalate (PET) recycled aggregate is addressed. The PET utilized was a waste fraction in the PET-bottle-recycling process. The implementation of waste in concrete mixes has a positive impact on their environmental and social profile; however, technical requirements are not necessarily met. In this investigation, PET was used as a substitute for fine aggregate in quantities ranging from 0 to 20% in increments of 5%. Both the flow properties of SCC mixes and the hardened SCC properties (compressive strength, splitting tensile strength, modulus of elasticity, and Poisson ratio) were investigated. Additionally, non-destructive tests (ultrasound and sclerometric) were performed to determine the correlation curves. The research revealed that both the flow properties and the parameters of the hardened concrete deteriorated with the PET content. Concrete with 20% PET replacement did not meet the self-compacting requirements and its compressive strength decreased by almost 50%. However, it was noted that replacing fine aggregate with PET aggregate in the amount of 5% did not significantly alter the concrete parameters and could be an attractive alternative to traditional concretes. Based on non-destructive testing, correlation curves were constructed that could be applicable to the future quality assessment of self-compacting concretes with recycled PET aggregate.     

Influence of Redispersible Powder on Properties of Self-Leveling Mortar of Ternary Cementitious System

The self-leveling mortar (SLM) of a ternary cementitious system with different dosages of redispersible powder (RP) with ordinary Portland cement (OPC), sulfoaluminate cement (SAC), and calcium sulfate (CS) as cementitious materials was investigated with regard to fluidity, bond strength, shrinkage rate, abrasion resistance, flexural strength, and compressive strength. The performance parameters obtained from the experimental test for SLM were weighted values calculated with an analytic hierarchy process (AHP). The comprehensive index of performance was evaluated on the basis of a weighted-sum method, and the optimal dosage of RP was determined according to the comprehensive index. The experimental results demonstrated that the fluidity of SLM decreased with the increase in RP dosage at the beginning but then increased thereafter and decreased rapidly as the dosage went beyond 3.0%. The addition of RP resulted in a significant improvement in bond strength (of SLM), reduction in the shrinkage rate, abrasion loss, early flexural strength and compressive strength, and resistance to cracking. The properties of SLM with 3.0% RP can meet the requirements of the industrial standard for cementitious self-leveling floor mortar. Compared with the SLM without RP, the bond strength of SLM with 3.0% RP was increased by 46.7%, while the shrinkage rate and abrasion loss were reduced by 50% and 71.9% respectively. The weighted values of fluidity, compressive strength, flexural strength, stability, cohesiveness, and abrasion resistance were 0.422, 0.196, 0.196, 0.089, 0.058, and 0.039, respectively. A higher value of the comprehensive index generally denotes a better performance. The comprehensive index of SLM with 3.0% RP was the highest.     

Evaluation of Eco-Efficient Concretes Produced with Fly Ash and Uncarbonated Recycled Aggregates

The fabrication of conventional concrete, as well as remains from demolition, has a high environmental impact. This paper assessed the eco-efficiency of concrete made with uncarbonated recycled concrete aggregates (RCA) and fly ash (FA). Two concrete series were produced with an effective water/cement ratio of 0.50 (Series 1) and 0.40 (Series 2). In both series, concretes were produced using 0% and 50% of RCA with 0%, 25% and 50% FA. After analysing the compressive strength, and carbonation and chloride resistance of those concretes, their eco-efficiency based on the binder intensity and CO₂-eq intensity was assessed. We found that the use of 50% uncarbonated RCA improved the properties of concretes produced with FA with respect to using natural aggregates. The concrete made of 25% FA plus RCA was considered the most eco-efficient based on the tests of compressive, carbonation and chloride properties with the values of 4.1 kg CO₂ m⁻³ MPa⁻¹, 76.3 kg CO₂ m⁻³ mm⁻¹ year^0.5 and 0.079 kg CO₂ m⁻³ C⁻¹, respectively. The uncarbonated RCA improved carbonation resistance, and FA improved chloride resistance. It can be concluded that the use of 50% un-carbonated RCA combined with FA considerably enhanced the properties of hardened concrete and their eco-efficiency with respect to concretes produced with natural aggregates.     

Properties and Strength Prediction Modeling of Green Mortar with Brick Powder Subjected to a Short-Term Thermal Shock at Elevated Temperatures

The cement industry is responsible for 8% of global CO₂ production. Therefore, a clear trend has been observed recently to replace to some extent the main binder of cement composites with environmentally friendly or recycled materials with a lower carbon footprint. This paper presents the effect of brick powder (BP) on the physico-chemical and mechanical properties of cement mortars. The effect of a short-term thermal shock on morphology and strength properties of green mortars was investigated. BP addition caused increase in porosity and decrease in compressive and flexural strength of mortars. The best results were obtained for samples with 5% wt. BP addition. Above this addition the strength decreased. The mechanical performance of the samples subjected to thermal loading increased compared to the reference samples, which is the result of a process called as the “internal autoclaving”. The BP addition positively affects the linear shrinkage, leading to its reduction. The lowest linear shrinkage value was achieved by the mortar with the highest BP addition. An intelligent modeling approach for the prediction of strength characteristics, depending on the ultrasonic pulse velocity (UPV) is also presented. To solve the model problem, a supervised machine-learning algorithm in the form of an SVM (support vector machines) regression approach was implemented in this paper. The results indicate that BP can be used as a cement replacement in cement mortars in limited amounts. The amount of the additive should be moderate and tuned to the features that mortars should have.     

Influence of Linseed Oil Varnish Admixture on Glauconite Clay Mortar Properties

Raw clay is used nowadays in construction as a component of mortars and plasters and as a binder in composites based on straw or shives. It is a material with good sorption properties and vapor permeability, but it is susceptible to shrinkage, is not resistant to water, and also is characterized by low mechanical strength, which makes it impossible to be used, for example, in external plasters. Various additives and admixtures are used to improve selected properties of clay mortars. The article presents the research results and assessment of the effect of glauconite clay mortar modification with an admixture of linseed oil varnish on selected properties. Admixtures in the amounts of 1%, 2%, and 3% in relation to clay weight were used. Flexural and compressive strength, water resistance, shrinkage, drying capacity, density, and porosity of mortar, were tested. The admixture of linseed oil varnish in the amounts used in the investigation had a positive effect on some of the tested properties; regardless of the quantity of the admixture, the modified mortars had better parameters concerning flexural strength, shrinkage reduction, and water resistance than the reference mortar, without admixture.     

Fresh,Mechanical, and Durability Properties of Self-Compacting Mortar Incorporating Alumina Nanoparticles and Rice Husk Ash

This paper presents a comprehensive evaluation on self-compacting (SC) mortars incorporating 0, 1, 3, and 5% alumina nanoparticles (NA) as well as 0% and 30% rice husk ash (RHA) used as Portland cement replacement. To evaluate the workability, mechanical, and durability performance of SC mortars incorporating NA and RHA, the fresh properties (slump flow diameter and V-funnel flow time), hardened properties (compressive strength, flexural strength, and ultrasonic pulse velocity), and durability properties (water absorption, rapid chloride permeability, and electrical resistivity) were determined. The results indicated that the addition of NA and RHA has negligible effect on the workability and water absorption rate of the SC mortars. However, significant compressive and flexural strength development was observed in the SC mortars treated with NA or the combination of NA and RHA. The introduction of RHA and NA also reduced the rapid chloride permeability and enhanced the electrical resistivity of the SC mortars significantly. It is concluded that the coexistence of 30% RHA and 3% NA as cement replacement in SC mortars can provide the best mechanical and durability performance.     

Research on the Properties and Mechanism of Carbon Nanotubes Reinforced Low-Carbon Ecological Cement-Based Materials

SAC (sulfoaluminate cement) has become a research hotspot as a low-carbon ecological cement. In addition, multi-walled carbon nanotubes have good thermal, mechanical, and electrical properties and can serve as excellent nano-reinforced cement-based fillers. This study explored the dispersion of carbon nanotubes (CNTs) and researched the effect of CNTs on the mechanical properties, hydration process, hydration products, and microstructure of SAC paste, and the mechanism of CNT-enhanced SAC paste was revealed. The results showed that the mechanical properties of SAC paste were significantly improved after the addition of CNTs. When the CNT content was 0.05%, 0.1%, and 0.15%, the compressive strength after 28 d was increased by 13.2%, 18.3%, and 22.5%, respectively; compared with the C0 group (without CNTs), the flexural strength increased by 8.2%, 11.3%, and 14.4%, respectively. The addition of CNTs accelerated the hydration process of SAC paste. Due to the adsorption effect and nucleation effect of CNTs, more hydration products were generated, filling the matrix’s pores and improving its compactness. The mechanism of CNTs enhanced SAC paste was revealed. CNTs and hydration products co-filled the pores, including AFt (ettringite) and AH₃ (gibbsite). CNTs improve the mechanical properties of SAC paste through filling, bridging, crack bending, deflection, pulling out, and pulling off.     

Properties of Foamed Mortar Prepared with Granulated Blast-Furnace Slag

Foamed mortar with a density of 1300 kg/m³ was prepared. In the initial laboratory trials, water-to-cement (w/c) ratios ranging from 0.54 to 0.64 were tested to determine the optimal value for foamed mortar corresponding to the highest compressive strength without compromising its fresh state properties. With the obtained optimal w/c ratio of 0.56, two types of foamed mortar were prepared, namely cement-foamed mortar (CFM) and slag-foamed mortar (SFM, 50% cement was replaced by slag weight). Four different curing conditions were adopted for both types of foamed mortar to assess their compressive strength, ultrasonic pulse velocity (UPV) and thermal insulation performance. The test results indicated that utilizing 50% of slag as cement replacement in the production of foamed mortar improved the compressive strength, UPV and thermal insulation properties. Additionally, the initial water curing of seven days gained higher compressive strength and increased UPV values as compared to the air cured and natural weather curing samples. However, this positive effect was more pronounced in the case of compressive strength than in the UPV and thermal conductivity of foamed mortar.     

Fundamental Properties and Self-Healing Performance of Repair Mortar with Solid Capsules Made Using Inorganic Reactive Powder

Self-healing cement composites are generally produced by using materials such as inorganic powders, bacteria pellets, and microcapsules. Among them, inorganic powder-type healing materials tend to decrease in healing performance over time because they react relatively quickly. Accordingly, this study encapsulated self-healing inorganic reactive powders in solid capsules (SC) in order to delay their reaction. The capsule surface was coated with a membrane to prevent moisture from permeating it. SC were utilized to provide the self-healing effect to the repair mortar. SC were mixed at three rates (0%, 5%, and 10%) by the binder mass of the repair mortar. The fundamental properties, including rheology, table flow, strength, and length change, and the self-healing performance of the self-healing repair mortar mixes were investigated. It was found that the rheological and mechanical properties of the repair mortar decreased slightly as the amount of SC increased. On the other hand, for a crack width of 0.25 mm and crack inducing age of 28 days, the healing performance of repair mortar specimens containing SC was at least 20 pt% better than that of plain repair mortar after a healing period of 28 days.     

Effect of Mechanically Treated Recycled Aggregates on the Long Term Mechanical Properties and Durability of Concrete

The objective of this research was to study the effect of an optimal mechanical treatment method to reduce the mortar adhered on recycled aggregates (RCA) on the long-term mechanical properties and durability of concretes containing RCA at different replacement levels. It was found that concretes incorporating treated RCA exhibited sharper and more significant increase on 90- and 365-day compressive strengths than any other investigated mixture. The same mixtures also benefitted from a ‘shrinkage-controlling’ effect, where strains and mass losses were reduced by almost 15% and 10%, respectively, compared to the reference concrete. While sulfate resistance and carbonation resistance are predominantly defined by the hydration products available within the cement paste and not to a large extent by the aggregate type and quality, the incorporation of either treated or untreated RCA in concrete did not appear to expose RACs to significant durability threats.     

Behaviour and Properties of Eco-Cement Pastes Elaborated with Recycled Concrete Powder from Construction and Demolition Wastes

This work analyses the influence of fine concrete fractions (<5 mm) of different natures —calcareous (HcG) and siliceous (HsT)—obtained from construction and demolition waste (C&DW) on the behaviour of blended cement pastes with partial replacements between 5 and 10%. The two C&DW fractions were characterised by different instrumental techniques. Subsequently, their lime-fixing capacity and the physico-mechanical properties of the blended cement pastes were analysed. Lastly, the environmental benefits of reusing these fine wastes in the manufacture of future eco-efficient cement pastes were examined. The results show that HsT and HcG exhibit weak pozzolanic activity, owing to their low reactive silica and alumina content. Despite this, the new cement pastes meet the physical and mechanical requirements of the existing regulations for common cements. It should be highlighted that the blended cement pastes initially showed a coarser pore network, but then they underwent a refinement process between 2 and 28 days, along with a gain in compressive strength, possibly due to the double pozzolanic and filler effect of the wastes. The environmental viability of the blended cements was evaluated in a Life Cycle Assessment (LCA) concluding that the overall environmental impact could be reduced in the same proportion of the replacement rate. This is in line with the Circular Economy goals and the 2030 Agenda for Sustainable Development.     

Coupling Influence between Recycled Ceramics and Grazed Hollow Beads on Mechanical Properties and Thermal Conductivity of Recycled Thermal Insulation Concrete

This paper investigated the influence of recycled ceramics and grazed hollow beads on the mechanical, thermal conductivity and material properties of concrete. The results showed that the concentration of recycled ceramics and grazed hollow beads has significant optimization on the workability and thermal properties of the concrete. However, the superabundant concentration can reduce the hydration degree of the concrete, which results in the suppressed production of C-S-H gel and the increase of material defects. In summary, considering the coordinated development of key factors such as thermal insulation properties, mechanical properties and microstructure, 10% RCE and 60% GHB are the optimal material system design methods.     

Effect of Cu on the Microstructure and Mechanical Properties of a Low-Carbon Martensitic Stainless Steel

Reversed austenite is of vital importance in low-carbon martensitic stainless steel because it improves impact toughness. However, a proper amount of reversed austenite is obtained by tempering at a critical temperature, which reduces the strength of the steel. Therefore, how to improve strength–toughness matching is an important problem. Copper (Cu) is an effective strengthening element in steels. However, there is little in-depth discussion on the role of Cu on the microstructure and mechanical properties of low-carbon martensite steel. In this work, the effect of different Cu content on the reversed austenite formation, tensile strength, and impact toughness of a low-carbon martensitic stainless steel (0Cr13Ni4Mo) was systematically investigated through use of a transmission electron microscope (TEM), transmission Kikuchi diffraction (TKD), atom probe tomography (APT), and other characterization methods and mechanical property tests. The results showed that the addition of Cu decreased the phase transition temperatures of martensite and austenite and increased the volume fraction of the reversed austenite. APT results indicated that Cu-rich clusters first formed with alloying elements such as ferrum (Fe) and nickel (Ni) and then grew to be precipitates through rejection of the alloying elements. The Ni atoms diffused towards the interface between the precipitates and the martensite matrix, which provided heterogeneous nucleation sites for the reversed austenite. Cu precipitations strengthened tensile strength during tempering. However, it generated temper brittleness in the steel at a tempering temperature of 450 °C, resulting in the impact energy of the 3Cu-steel being only 7 J. A good combination with higher tensile strength (863 MPa) and ductility (192 J) was obtained when tempering at 600 °C in the presence of Cu-rich precipitates and a sufficient volume fraction of the reversed austenite. The results provide guidance for the design of steels with reversed austenite and Cu and promote the development of high-strength and high-toughness steels.     

Strength and Water-Repelling Properties of Cement Mortar Mixed with Water Repellents

In this study, the compressive strength and water contact angle of mortar specimens prepared by mixing two types of water repellent with ordinary Portland cement (OPC) and rapid-hardening cement mortar were measured before and after surface abrasion. In addition, the hydration products and chemical bonding of cement mortar with the repellents were examined using X-ray diffraction (XRD), thermogravimetry-differential thermal analysis (TG-DTA), and Fourier-transform infrared spectroscopy (FT-IR) to evaluate the performance of these cement mortar mixtures as repair materials. We found that the fast-hardening cement mortar mixture containing the oligomer water repellent showed the best performance with a high compressive strength and large water contact angle. With the oligomer water repellent, the rapid-hardening cement mortar mixture showed contact angles of 131° and 126° even after a 2 mm abrasion, thereby confirming that the water repellent secured hydrophobicity through strong bonding with the entire cement mortar as well as its surface. The compressive strengths were found to be 34.5 MPa at 3 h and 54.8 MPa at 28 days, confirming that hydration occurred well despite the addition of water repellent.     

An Investigation of Mechanical Properties of Recycled Carbon Fiber Reinforced Ultra-High-Performance Concrete

Carbon fiber-reinforced concrete as a structural material is attractive for civil infrastructure because of its light weight, high strength, and resistance to corrosion. Ultra-high performance concrete, possessing excellent mechanical properties, utilizes randomly oriented one-inch long steel fibers that are 200 microns in diameter, increasing the concrete’s strength and durability, where steel fibers carry the tensile stress within the concrete similar to traditional rebar reinforcement and provide ductility. Virgin carbon fiber remains a market entry barrier for the high-volume production of fiber-reinforced concrete mix designs. In this research, the use of recycled carbon fiber to produce ultra-high-performance concrete is demonstrated for the first time. Recycled carbon fibers are a promising solution to mitigate costs and increase sustainability while retaining attractive mechanical properties as a reinforcement for concrete. A comprehensive study of process structure–properties relationships is conducted in this study for the use of recycled carbon fibers in ultra-high performance concrete. Factors such as pore formation and poor fiber distribution that can significantly affect its mechanical properties are evaluated. A mix design consisting of recycled carbon fiber and ultra-high-performance concrete was evaluated for mechanical properties and compared to an aerospace-grade and low-cost commercial carbon fiber with the same mix design. Additionally, the microstructure of concrete samples is evaluated non-destructively using high-resolution micro X-ray computed tomography to obtain 3D quantitative spatial pore size distribution information and fiber clumping. This study examines the compression, tension, and flexural properties of recycled carbon fibers reinforced concrete considering the microstructure of the concrete resulting from fiber dispersion.     

The Performance of Concrete Made with Secondary Products—Recycled Coarse Aggregates,Recycled Cement Mortar,and Fly Ash–Slag Mix

The properties of cement concrete using waste materials—namely, recycled cement mortar, fly ash–slag, and recycled concrete aggregate—are presented. A treatment process for waste materials is proposed. Two research experiments were conducted. In the first, concretes were made with fly ash–slag mix (FAS) and recycled cement mortar (RCM) as additions. The most favorable content of the concrete additive in the form of RCM and FAS was determined experimentally, and their influence on the physical and mechanical properties of concrete was established. For this purpose, 10 test series were carried out according to the experimental plan. In the second study, concretes containing FAS–RCM and recycled concrete aggregate (RCA) as a 30% replacement of natural aggregate (NA) were prepared. The compressive strength, frost resistance, water absorption, volume density, thermal conductivity, and microstructure were researched. The test results show that the addition of FAS–RCM and RCA can produce composites with better physical and mechanical properties compared with concrete made only of natural raw materials and cement. The detailed results show that FAS–RCM can be a valuable substitute for cement and RCA as a replacement for natural aggregates. Compared with traditional cement concretes, concretes made of FAS, RCM, and RCA are characterized by a higher compressive strength: 7% higher in the case of 30% replacement of NA by RCA with the additional use of the innovative FAS–RCM additive as 30% of the cement mass.     

Study on the Mechanical Properties,Wear Resistance and Microstructure of Hybrid Fiber-Reinforced Mortar Containing High Volume of Industrial Solid Waste Mineral Admixture

The use of a high volume of industrial solid waste mineral admixture and hybrid fiber can greatly reduce the amount of cement in mortar or concrete, improve its performance, ensure the service properties of mortar or concrete, and reuse industrial solid waste to reduce the environmental burden, which has significant research significance. In this paper, the mechanical properties, wear resistance and microstructure of hybrid fiber-reinforced mortar (HFRM) with a high content of industrial solid waste mineral admixture were systematically studied under different water/binder ratios. Mineral admixtures include fly ash, silica fume and granulated blast furnace slag (slag). The total content of hybrid glass fiber (GF) and polypropylene fiber (PPF) was 2% by volume fractions, and six different water/binder ratios ranging from 0.27 to 0.62 were used. The following conclusions were drawn: fibers have a significant negative effect on the properties of mortars with a low water/binder ratio (w/b = 0.27) and high content of mineral admixtures. In general, the effect of adding hybrid fiber on improving the wear resistance of mortar is more obvious. The average residual weight of hybrid fiber-reinforced mortar is the highest after the wear resistance test. Comprehensively considering the compressive strength, flexural strength, wear resistance and microstructure of the mortar samples, G8PP2-0.40 is the optimal mix ratio. At this time, the replacement rates of fly ash, silica fume and slag are: 20%, 5% and 30%, the water/binder ratio is 0.40, and the content of GF and PPF is 1.6% and 0.4%, respectively.     

Development of Fibre-Reinforced Cementitious Mortar with Mineral Wool and Coconut Fibre

Globally, as human population and industries grow, so does the creation of agricultural, industrial, and demolition waste. When these wastes are not properly recycled, reused, or disposed of, they pose a threat to the environment. The importance of this study lies in the beneficial use of coconut fibre and mineral wool in the form of fibres in cement mortar production. This study examines the use of coconut and mineral wool fibres in the production of fibre-reinforced mortar. Five different mortar mixtures were prepared, having one control mortar along with four fibre-reinforced mortars. The control mortar is denoted as CM while 1% and 1.5% of mineral wool are incorporated into this mortar mix and denoted as RMM-1.0 and RMM-1.5, respectively. Additionally, the mortar sample configurations contain 1% and 1.5% coconut fibers, designated as RCM-1.0 and RCM-1.5. These samples were subjected to different strength and durability tests to determine their suitability for use in mortar production. The testing findings show that mortar containing 1.5% mineral wool has better compared flexural strength and durability properties. The investigation results will form part of the database for the efficient utilization of natural and waste fibres in the construction and building sectors.     

Comparative Study of Effects of Air-Entraining Plasticizing Admixture and Lime on Physical and Mechanical Properties of Masonry Mortars and Plasters

This article presents research on selected physical and mechanical properties of cement-based plasters and masonry mortars with consistency-improving additives, namely, traditional hydrated lime and a plasticizing and aerating mixture (APA), which, in practice, is often considered to be a lime substitute. Comparative analysis of the properties of mortars with alternative additives—lime or APA—was carried out, taking into consideration possible effects of cement, as two types of Portland cement were used for the research. For fresh mortar, mixture consistency, air content, resistance to segregation, and water retention were determined. Tests on hardened mortars included tests of porosity and impermeability, depth of penetration of water under pressure, drying shrinkage, as well as compressive and bending strength, modulus of elasticity, and adhesion of mortars to the base. In addition, research has shown that cement–lime mortars and cement mortars with APA admixture of similar consistency in the fresh state are characterized by significantly different properties. The results show, in most of the features analyzed, more favorable properties of mortars with the use of traditional lime. For shrinkage only, the use of admixture turned out to be more advantageous.